PHASE 1
(Triangulation of the frame) Date Started : November 15, 2008 |
PRINTS :
G1-1 The keel ---------- ****Note changes ****
G1-2 The Mast piece ------- ****Note Changes *****
G1-3 Cluster plates
G1-4 The seat brackets
G1-5 The Frame assembly
HARDWARE :
2 ----- AN4-26A ---- Bolts
4 ----- AN960-416 -- Washers
2 ----- AN365-428 -- Nylon lock nuts
7 ----- AN3-26A -----Bolt
14 ---- AN960-316 -- Washers
7 ----- AN365-1032 -- Nylon lock nuts
MATERIALS :
Keel tube
1------- 2" x 2" x 1/8" x 72" length -Grade 6061-T6 Aluminum tubing ---
Mast tube
1------- 2" x 2" x 1.88" x 72" length -Grade 6061-T6 Aluminum tubing --- ****Note Changes****
Keel / mast cluster plates
2------- 2" x 7" x 1/8" Thickness-Grade 6061-T6 Aluminum sheet stock--
Seat braces
2------- 1" x 1" x 1/8" x 44-�" length - Grade 6061-T6 Aluminum angle ---
BUILDING THE FRAME :
I started on the Keel tube I drilled them per the drawings.
Picture #1 Picture #2
Cutting out the mast section :
Since I am going to have a split mast to fold down to put into the garage I am going to need to cut the mast ??" from the top of the mast using a ?? angle of a cut. It is best to have a solid 72" piece when you make the cut so that the 2 pieces are married together. .
Cutting the mast Cleaning up Look good Split mast
Picture #3 Picture #4 Picture #5 Picture #6
Making the Split mast cheek plates :
I used 2024-T6 for the 2 cheek plate on the split mast. Also make 2 of the 1-1/4" solid round spacers to go inside the 2" mast tubing. The 2 pieces will act as a support on the inside when you tighten the AN5 bolts.
Picture #7 Picture #8 Picture #9
SEAT BELT PLATES :
Cutting the 2 sets of Cheek plates out for the bottom or hip belts and I need to make a T for the top shoulder harness straps.
The is the next change to the plans, we will not use Stainless steel we will use 3/16"-- 6061-T6 -- flat plate aluminum-- for the bottom lap belts and 1/2" x 2"-- 6061-T6 -- flat bar aluminum-- for the shoulder harness.
OTHER MATERIALS :
4 ---Cans of etching primer NAPA
1 ---Quart can of sealer for the etching primer CS-279 part 1 of 2 NAPA
1 ---Pint can of reducer CR-233 part 2 of 2 NAPA
1 ---Gallon of Sunset Red paint that I bought last year for the old truck.
1 ---Gallon of reducer/ activator
1 ---Quart of fisheye killer
1 ---Bag of rags Wal-mart
1 ---Gallon can of Acetone to clean the parts Wal-mart
1 ---Pack of scotch bright pads Wal-mart
1 ---Pack of chemical gloves Wal-mart
1 ---Razor Knife Wal-mart
1 ---Caliper ruler LOWES
1 ---Pack of 320 grit sand paper Wal-mart
Cutting all the parts out to build the Gyrobee / Dogbee gyro.
Total hours :
Cleaning the metal time for all parts: 3 hours
December 16, 2008
Got the cleaning supplies out and went to work stripping all the aluminum to get it ready to paint. That acetone stuff is pretty strong it ate right through my PVC gloves that I had bought. Took me a few hour to disassemble all the parts and photo all the parts. Got to get some etching prime to paint the aluminum parts, NAPA has some in cans that you can use like spray paint. The sealer will have to be bought in quart can and comes with a reducer. Not sure how much that is going to be.
I will find out tomorrow when I go by there after work. Called around today about taking some flying lesson there are 2 instructor about the same distance. One is 150.00 per hour the other one is 170.00 per hour. Lots of time to think about getting some training when it starts to warm up a bit in the spring.
December 17, 2008
Came home from work and finished taking all the rest of the part apart to clean them with the Acetone. Also got to pick up the Etching Primer and some 320 grit sand paper. I brought out a hand full of cloth hangers to hang the parts up with. I made little hooks out of them, as you can see from all the parts hanging.
Premium Self-Etching Primer: -- Etches and primes in one easy step. Can be used under all today s automotive finishes. Perfect for spot repairs. Creates superior adhesion on most plastics, fiberglass, bare steel, aluminum and stainless steel.
Picture #11 Picture #12 Picture #13 Picture #14
December 21, 2008
Spent most of the day spray the Etching Primer Sealer on all the parts again to get ready for the paint tomorrow. I had to rig me up a place to hang all the small part I spray. It looked like I was making a new type of wind chime.
Picture #15 Picture #16
Primer time for all parts: 2 hours
Sealer time for all parts: 2 hours
Time to paint all the parts now, boy this is the bad part. I thought cleaning, sanding, etching prime and etching sealer was bad. Making all the trips in and out the door to paint was a killer. The wind was blowing to bad to hang everything out to dry or paint this morning. I did the first coat of paint on everything be 9:00AM. By 2:00 everything was dry to the touch so I put the first coat of clear on it to give it a good shine. I will need to put one more coat of clear on it tomorrow.
Painting time for all parts: 2 hours
Clear coat time for all parts: 2 hours
December 22, 2008
I want to see if I need to put one more coat of clear on the paint job or not or just start putting it together. Like to see what it is going to look like. I have not figured out what other color I was going to use with the Red to offset it.
Picture #17 Picture #18 Picture #19
Bright yellow was my first choice!
Need to go to Lowes and pickup a sheet of 1" or 2" foam sheeting for my tail section. Also some fiberglass matting and other item need to get it started. I wonder if I should get some color to put in the epoxy resin so that I will have color through out the tail just in case it get chipped?
Not sure if you can I have to read up on this stuff.
December 23, 2008
Weather was a little cold so I had to keep the garage door shut to keep the heat in. Spent all day putting everything back together I started around 6:30AM it went kind of fast going back together.
Picture #20 Picture #21 Picture #22
Picture 1: Just got started when I heard a scratch at the door. It was the inspector. Come to check on me. Installing the keel and mast. I had to put one axle on to help keep everything stable.
Still having a few problems with the pedals, I am trying to get some good pictures of them. I think it took me 3 hours to reassemble all the part to bring it back together Had to be slow as not to scratch the paint.
Reassemble time for all frame parts: 3 hours